M.

Teresa Ferraz and Manuela Oliveira Hydrogen embrittlement

STEEL FASTENERS FAILURE

BY HYDROGEN EMBRITTLEMENT
M. TERESA FERRAZ, MANUELA OLIVEIRA*

INETI-DMTP, LCM – Laboratório de Caracterização de Materiais, Estrada do Paço do Lumiar, 1649-038 Lisboa
teresa.ferraz@ineti.pt

ABSTRACT: his paper details the analysis carried out on two failed bolts to find out the reason for failure, using
macrofractography, optical metallography and scanning electron microscope (SEM) techniques. Usual measures to preventt
such failures are also referred. Similar fractures occurred at the head to shank transition of the bolts during fastening, orr
afterwards, while waiting for delivery. Since failure occurred in a region where foreseen stresses were quite below yield
strength and there was no evidence of mechanical deformation, embrittlement was suspected. SEM observation of the
fracture surface crack initiation region showed areas of intergranular crack propagation indicating brittleness, and higherr
magnification observation showed hydrogen embrittlement features. The bolts, which microstructure was typically that off
hardened and tempered steel, had been zinc electroplated and it is well known that hydrogen release concurs with zinc
deposition. Moreover, the diffusion and accumulation of the hydrogen in metals is favoured by cold working, as is the case
of the head to shank transition region.

Keywords: Hydrogen embrittlement, failure, steel, fractography, scanning electron microscopy

RESUMO: Este artigo apresenta a análise efectuada em dois parafusos fracturados, com o objectivo de determinar as
causas da fractura, usando técnicas de macrofractografia, metalografia óptica e microscopia electrónica de varrimento.
Também são referidas as precauções habituais para evitar este tipo de falha. As fracturas, semelhantes entre si,
ocorreram na transição entre a cabeça e o corpo do parafuso, durante ou após a operação de aperto. Uma vez que as
fracturas apareceram numa região em que as tensões previstas estariam bastante abaixo da tensão de cedência e não se
observava deformação mecânica, a fragilização foi desde logo uma possível suspeita. A observação da superfície na
zona de iniciação da fractura, por microscopia electrónica de varrimento, revelou zonas de propagação intergranular de
fissuras, apontando para uma fragilização, sendo possível observar aspectos típicos de fragilização por hidrogénio a
ampliações mais elevadas. Os parafusos, cuja microestrutura correspondia à de um aço temperado e revenido, tinham
sofrido um tratamento superficial de zincagem. Sabe-se que, durante estes tratamentos, a libertação de hidrogénio
compete com a deposição do zinco e, além disso, a difusão e acumulação do hidrogénio nos metais é favorecida pela
deformação a frio, o que é precisamente o caso da zona de transição cabeça/corpo de um parafuso.

Palavras chave: Fragilização por hidrogénio, falha, aço, fractografia, microscopia electrónica de varrimento

1. INTRODUCTION solutions and conditions to produce high cathode efficiency

Zinc electroplated steel fasteners are widely used for
assembling threaded joints, since zinc is anodic to steel and
offers both good protection to atmospheric corrosion and
good appearance, even when applied in thin films in order to
obey the dimensional tolerances imposed to fasteners.
Moreover, acid zinc plating baths developed since the
1970’s made the process low-cost and easily applied in
barrel or continuous procedures [1].
in order to minimize the amount of hydrogen generated on
the metal, a proper elevated-temperature (180-230 ºC, lower
to tempering temperature) baking heat treatment is generally
required for hydrogen removal. The treatment must be
applied for several hours, generally a minimum of 4 hours is
specified (because the metallic coating plated on metal often
acts as barrier to hydrogen diffusion [3]), and in a few hours,
or immediately, after electroplating and before any further
treatment is applied.

However, when high strength steel fasteners are required,
such as ISO 898-1 grade 10.9 or higher, for which nominal
tensile strengths over 1000 MPa are specified, bolts are
made of quenched and tempered steel [2], and electroplating
presents a high risk of hydrogen embrittlement. It is well
known that during zinc electroplating hydrogen release
concurs with zinc deposition. Besides selecting plating
Hydrogen embrittlement is a well-known phenomenon in
which a metal is weakened by the incorporation of hydrogen
in or below its surface, e.g. during plating or etching.
Hydrogen diffuses easily into the metal crystalline structure
either as atoms or protons. Non-metallic inclusions such as
sulphides, as well as phosphorus, favour hydrogen
adsorption, acting as catalysts. Grain boundaries and other

128 Ciência e Tecnologia dos Materiais, Vol. 20, n.º 1/2, 2008
Hydrogen embrittlement
lattice defects are also regions where hydrogen diffuses and
accumulates easily, hence preferential for hydrogen
embrittlement to occur. Hydrogen diffusion is also easier in
all regions where the crystalline structure may be distorted
as a result of work hardening or cold deformation. The
accumulation of hydrogen restricts ductility and promotes
brittleness.
Hardened and tempered steels need only a few p.p.m. of
hydrogen to cause embrittlement [3, 4].
Failure induced by hydrogen is favoured or caused by
applied stresses, even static or of low intensity, and is
often referred to as “delayed” or “retarded”, since it may
not take place immediately after tensile stresses are
applied. This type of embrittlement is not detectable by
hardness determinations, but tensile tests will show
considerable reduction of the expected tensile strength of
the material [5].
This work presents a case study where premature fragile
failure of several bolts occurred, during assembly of
components, or afterwards while waiting for delivery
(delayed failure), at low stresses, quite below the specified
proof stress.
2. FAILURE ANALYSIS
The fractures occurred at the head to shank transition of
several steel fasteners used to fix an engine to its base. The
following items and information were provided for failure
analysis:
- Photographs of a component with a fractured bolt inside
and of two fractured bolts (Fig. 1);
- two fractured bolts (head and shank);
- bolts were supposed to be class 10.9 (ISO 898-1) and
zinc electroplated.
Fig. 1. General view of two fractured bolts
Preliminary visual inspection off the fractured bolts showed
that:
- All bolts failed in a similar way;
- fractured surfaces were similar and the rupture had
occurred apparently without necking (plastic
Ciência e Tecnologia dos Materiais, Vol. 20, n.º 1/2, 2008
M. Teresa Ferraz and Manuela Oliveira
deformation) in the transition zone between head and
shank;
- there was no general oxidation and/or corrosion;
- fracture surfaces were quite smooth and normal to the
direction of the applied loads, except for the central part
corresponding to the end of fracture;
- fractures seemed to have had its origin all around the
circular external bolt surface, where several initiating
zones were observed.
The following tests were carried out:
- Fractographic examination of both bolts fracture
surfaces at low magnifications (3 to 20 times) with an
optical stereomicroscope and also at higher
magnification with a SEM (20 to 10000 times) after
ultrasonic cleaning in an ethylic alcohol bath.
- Metallographic examination by optical microscopy of
the fractured bolts microstructure on longitudinal
sections from the head and shank part nearest to the
head taken through the bolt axis.
- Rockwell C hardness determinations on a cross section
of the shank.
3. RESULTS
3.1. FRACTOGRAPHY
Observations at low magnification (Fig. 2) showed that:
- Fracture characteristics were similar in both bolts
indicating that failure must have occurred by the same
causes;
- the fractures were almost parallel to the cross section,
and occurred with no evidence of deformation or
distortion near the origin;
- the fracture surfaces were nearly flat with several crack
initiation zones all around the external bolt surface;
- origins were located at slightly different levels and after
a short propagation cracks joined together in a common
front;
- the fracture surface area corresponding to this first stage
of propagation showed the smoothest surface on fig. 2
b) and 2 c);
- cracks continued to propagate towards the centre, and
fracture surfaces became rougher;
- final rupture occurred by overload shear and showed a
change in crack propagation direction towards the top
of the bolt head;
- both fractures occurred almost instantaneously after
cracking initiation due to the applied stresses.
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M. Teresa Ferraz and Manuela Oliveira Hydrogen embrittlement

characteristics are more pronounced as grains seemed

more individualized;
- at the end of the propagation failure process, close to
the centre of the bolts, the fracture surface showed a
typical dimpled configuration with elongated cavities
(fig. 5);

a)

Init

a)

b)

c)
Fig. 2. Fractured bolt: a) General side view of facture
surface, shank side; b) details of fracture initiation zones at
head-shank transition surface, shank side; c) details of
fracture initiation zones at head-shank transition surface,
head side.
b)
Fig. 3. SEM observation of one of the bolts fracture
surfaces: a) overall view of initiation zones near shank
external surface; b) detail from marked area, fracture
propagation partially intercrystalline and transcrystalline,
intergranular zones showing intercrystalline subsidiary
cracking, micro-pores and ductile hair lines at the former
austenite grain boundaries.

SEM allowed further information about surface fracture

features (Fig. 3, 4 and 5):
- Cracking initiation zones and zones near the surface
presented both intergranular and transgranular crack
propagation;
- crack growth zones showing intergranular features also
presented intercrystalline subsidiary cracking (or
yawning grain boundaries), and micro-pores and ductile
hair lines, often branched forming crow feet marks, at
prior austenite grain boundaries [6];
- intergranular fracture surfaces zones showed some
small areas, looking like nests, where intercrystalline

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a)
b)
c)
d)
Fig. 4. SEM observation of the other bolt fracture surfaces:
a) and c) general view at the initiation zone near the external
surface of the shank; b) and d) details from marked zones
with pronounced intercrystalline characteristics showing
grain surface features like micro-pores and ductile hair lines
at the former austenite grain boundaries.
Ciência e Tecnologia dos Materiais, Vol. 20, n.º 1/2, 2008
M. Teresa Ferraz and Manuela Oliveira
Fig. 5. SEM observation of fractured surfaces: dimpled
rupture fracture surface at final rupture zone near bolt centre
3.2. OPTICAL MICROSCOPY
Metallographic examination of the longitudinal sections
from the head and the shank showed the typical
microstructure of hardened and tempered steel, with no
visible external surface decarburization (Fig. 6) or
continuous carbide precipitation along grain boundaries
(Fig. 7).
Fig. 6. Metallography of the shank cross section: external
surface and initiation of fracture zone from the fracture
surface
At the initiation zone, fracture surface was flat and rather
smooth and there was no fracture branching neither oxides
deposits nor decarburization over the fracture surface. Some
small intercrystalline subsidiary cracking was detected on
fracture surface grains.
There were several inclusions of the sulphide (type A) and
oxide (type D) types, but always below the 2 ½ index of the
JK chart (plate I ASTM E45) for type A inclusions and
below 1 ½ for type D.
Few non-metallic inclusions appeared cracked or debonded
from the matrix, indicating lack of ductility. Fig. 7
exemplifies one agglomerate of inclusions, cracked and
debonded from the matrix, and seeming to originate a
micro-crack, almost 50 ȝm long, with rather sharp tips.
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M. Teresa Ferraz and Manuela Oliveira
Fig. 7. Metallography of the shank cross section just below
fracture surface: sulphide and oxide non metallic inclusions
and a set of cracked and/ or debonded inclusions, resulting
into a micro crack.
3.3. ROCKWELL HARDNESS
The determinations were carried out at a cross section cut at
approximately 1,5cm from the end of the thread. The
average value obtained was 36,2 ± 3,1 HRC (95% mean
confidence level), value which is within the range specified
for grade 10.9 bolts (32 to 39 HRC, after ISO 898-1 [2]).
4. DISCUSSION
The failure analysis here reported involves high strength
steel fasteners grade 10.9 [2], heat treated (quenched and
tempered), in order to achieve the specified high strength
levels. The hardness values determined were in the range
specified for this class of bolts (class 10.9, 32 to 39 HRC).
The flatness of fracture surfaces, the serial failures and the
fact that failure process took place in a region where, when
in service, expected tensile stresses are considerably lower
(at least twice to three times lower) than those expected after
fastening in the threaded shank zone at the first thread inside
the nut, pointed out to a manufacture or material defect or to
an embrittlement phenomenon as causes for failure.
The microstructure observed corresponded to hardened and
tempered steel, without detectable preferential carbide
precipitation along previous austenite grain boundaries, so
carbide embrittlement was excluded. Surface
decarburization was not detected either.
Inclusion content of the steel was far below the maximum
limits accepted for this kind off application. Forging defects,
cracks or other discontinuities, that could have acted as stress
concentrators or raisers were also not observed. Finally, there
was not oxidation of the fracture surface, or crack branching
along grain boundaries, which would indicate quenching
cracking or a stress corrosion crack process.
The observation of the fracture surfaces carried out in the
SEM showed that, starting at the external surface, crack
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Hydrogen embrittlement
growth occurred intergranularly, indicating embrittlement.
Typical features of hydrogen embrittlement were observed
in the fracture surfaces of both bolts, as described above.
Bolts manufacturing process can produce highly non-
uniform deformation, as shown in Fig. 8. The head region
and in particular the head/shank interface can undergo
significant cold work hardening raising the tensile strength
in these regions considerably in excess of the 1000 MPa [4]
specified. At these high strength levels, subsequent
electroplating brings a serious risk of hydrogen
embrittlement. The deformed microstructure which resulted
from the manufacturing process, highly distorted and having
high concentration of lattice defects like vacancies and
dislocations, favours the diffusion and concentration of the
hydrogen released during electroplating.
Fig. 8. Bolts cross section macrostructure showing the
deformation lines produced by head forging due to non-
uniform deformation
The diatomic hydrogen molecule is too large to enter the
surface of a solid metal and diffuse interstitially. However,
in the dissociated form, single atoms are relatively mobile,
even at room temperature [4]. One way to produce atomic
hydrogen is the cathode reaction competing with metal
deposition in an electroplating process (equations (1) and
(2)):
Zn2+ + 2e- = Zn0 (1)
2 H+ + 2e- = H2 (2)
Therefore, the electrolytic process must be controlled,
namely high efficiency procedures must be used, current
intensity and bath impurities controlled and good agitation
provided in order to liberate the hydrogen bubbles formed
over the cathode surface. The control may not always be
efficient in order to prevent hydrogen from concentrating in
microstructure defects and some hydrogen may be
inevitably present.
The solubility of hydrogen decreases with temperature and
hydrogen accumulated in lattice defects may precipitate in
gaseous form, originating a pressure high enough to produce
small cracks. This can however be avoided by a post plating
baking treatment to remove hydrogen prior to service [3,4].
Zinc electroplated components must undergo the treatment
at temperatures around 200oC, for several hours and
immediately or shortly after plating.
Internal hydrogen embrittlement has been known for years,
but is far away from being banished or even controlled.
Some components may require longer baking times due to
Ciência e Tecnologia dos Materiais, Vol. 20, n.º 1/2, 2008
Hydrogen embrittlement
more gas evolution during plating or to thicker and less
permeable coatings. To prevent risk of failure due to
improper baking after electroplating, standardized tests on
samples may be conducted [7,8]. Another alternative is to
choose a coating procedure without hydrogen embrittlement
risk.
5. CONCLUSIONS
Hydrogen embrittlement remained as the only probable
cause of the failure observed. Unlike stress corrosion
cracking and quenching cracks, cracks caused by hydrogen
embrittlement usually do not branch [3] neither show
oxidized surfaces. Typical features of hydrogen
embrittlement were observed on the fracture surfaces of both
bolts.
Bolts had been zinc electroplated, which is one way to
introduce hydrogen into metals, and baking treatment after
plating may not have been well conducted.
ACKNOWLEDGEMENTS
The authors thank LCM collaborators Maria Pinho
(metallographic preparation), Paulino Verdasca (hardness
tests) and also Susana Dias, M.Sc, (scanning electron
microscopy).
6. REFERENCES
[1] Geduld, H.H., “Zinc Plating”, in “Metals Handbook”,
Ninth Edition, Vol. 5, 244-255, American Society for
Metals, Metals Park, Ohio, U.S.A. (1982).
Ciência e Tecnologia dos Materiais, Vol. 20, n.º 1/2, 2008
M. Teresa Ferraz and Manuela Oliveira
[2] ISO 898-1:1999, “Mechanical properties of fasteners
made of carbon steel and alloy steel – Part 1: Bolts,
screws and studs.
[3] Kim, C.D., “Hydrogen-Damage Failures”, in “Metals
Handbook”, Ninth Edition, Vol 11, 245-251, American
Society for Metals, Metals Park, Ohio, U.S.A. (1986).
[4] T.J. Carter, L.A. Cornish, “Hydrogen in metals”,
Engineering Failure Analysis, 8 (2001) 113-121.
[5] Trowsdale, A.J. and Pritchard, S. B., “Dual phase steel
– High strength fasteners without heat treatment”,
Corus Construction& Industrial, UK, Internal
Communication.
[6] Engel, L. and Klingele H., “Damage mechanisms and
their appearance – Fracture caused by combinations of
mechanical loading and chemical attack” chapter 3,
pp. 105-132 in “An atlas of metal damage- surface
examination by scanning electron microscope”
translated by Stuart Murray ed. Wolfe Science Books
in association with Carl Hanser Verlag, Munich,
Vienna, 1984.
[7] ASTM F 1940-07a “Standard Test Method for Process
Control Verification to Prevent Hydrogen
Embrittlement in Plated or Coated Fasteners”
[8] ISO 15330:1999 “Fasteners – Preloading test for the
detection of hydrogen embrittlement – Parallel bearing
surface method”
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